Batteries

ABSTRACT

Batteries and related components and methods are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of and claims priority toU.S. Provisional Application No. 60/711,007, filed on Aug. 24, 2005,which is hereby incorporated by reference.

TECHNICAL FIELD

The invention relates to batteries, and to related components andmethods.

BACKGROUND

Batteries, such as alkaline batteries, are commonly used as electricalenergy sources. Generally, a battery contains a negative electrode(anode) and a positive electrode (cathode). The anode contains an activematerial (e.g., zinc particles) that can be oxidized; and the cathodecontains an active material (e.g., manganese dioxide) that can bereduced. The active material of the anode is capable of reducing theactive material of the cathode. In order to prevent direct reaction ofthe active material of the anode and the active material of the cathode,the electrodes are electrically isolated from each other by a separator.

When a battery is used as an electrical energy source in a device, suchas a cellular telephone, electrical contact is made to the electrodes,allowing electrons to flow through the device and permitting therespective oxidation and reduction reactions to occur to provideelectrical power. An electrolyte in contact with the electrodes containsions that flow through the separator between the electrodes to maintaincharge balance throughout the battery during discharge.

SUMMARY

The invention relates to batteries, and to related components andmethods.

In one aspect, the invention features a battery including a housing, ananode and a cathode within the housing, and a current collector at leastpartially disposed in the anode. The current collector includes a fusehaving a fusing element with a melting point of at least about 200° C.(e.g., at least about 300° C., at least about 400° C., at least about500° C., at least about 600° C., at least about 800° C., at least about1000° C., at least about 1100° C., at least about 1200° C., at leastabout 1400° C., at least about 1600° C., at least about 1800° C., atleast about 1900° C.).

In another aspect, the invention features a battery including a housing,an anode and a cathode within the housing, and a current collector atleast partially disposed in the anode. The current collector includes afuse including a fusing element. The fusing element is adapted to meltat a temperature of at least about 200° C. (e.g., at least about 300°C., at least about 400° C., at least about 500° C., at least about 600°C., at least about 800° C., at least about 1000° C., at least about1100° C., at least about 1200° C., at least about 1400° C., at leastabout 1600° C., at least about 1800° C., at least about 1900° C.) whilethe housing is at a temperature of at most about 90° C. (e.g., at mostabout 80° C., at most about 70° C., at most about 60° C., at most about50° C., at most about 40° C., at most about 30° C., at most about 25°C.).

In a further aspect, the invention features a battery including ahousing, an anode and a cathode within the housing, and a currentcollector at least partially disposed in the anode. The currentcollector includes a fuse having a fusing element with a width ordiameter of at most about 1.5 millimeters.

In an additional aspect, the invention features a method of making abattery. The method includes disposing an anode, a cathode, and acurrent collector into a housing. The current collector includes anelongated body and a fuse at least partially disposed in the elongatedbody. The fuse includes a fusing element with a melting point of atleast about 200° C. (e.g., at least about 300° C., at least about 400°C., at least about 500° C., at least about 600° C., at least about 800°C., at least about 1000° C., at least about 1100° C., at least about1200° C., at least about 1400° C., at least about 1600° C., at leastabout 1800° C., at least about 1900° C.).

In a further aspect, the invention features a method of making abattery. The method includes disposing an anode, a cathode, and acurrent collector into a housing. The current collector includes a fuseincluding a fusing element. The fusing element is adapted to melt at atemperature of at least about 200° C. (e.g., at least about 300° C., atleast about 400° C., at least about 500° C., at least about 600° C., atleast about 800° C., at least about 1000° C., at least about 1100° C.,at least about 1200° C., at least about 1400° C., at least about 1600°C., at least about 1800° C., at least about 1900° C.) while the housingis at a temperature of at most about 90° C. (e.g., at most about 80° C.,at most about 70° C., at most about 60° C., at most about 50° C., atmost about 40° C., at most about 30° C., at most about 25° C.).

In an additional aspect, the invention features a method of making abattery. The method includes disposing an anode, a cathode, and acurrent collector into a housing. The current collector includes anelongated body and a fuse at least partially disposed in the elongatedbody. The fuse includes a fusing element having a width or diameter ofat most about 1.5 millimeters.

In another aspect, the invention features a method that includes flowinga current through a battery. The battery includes a housing, an anodeand a cathode within the housing, and a current collector at leastpartially disposed in the anode. The current collector includes anelongated body, in which a fuse including a fusing element is at leastpartially disposed. The method also includes increasing the temperatureof the fusing element by at least about 100° C. (e.g., at least about200° C., at least about 300° C., at least about 500° C., at least about700° C., at least about 900° C., at least about 1000° C., at least about1100° C., at least about 1300° C., at least about 1500° C., at leastabout 1700° C., at least about 1900° C.) while the temperature of thehousing increases by at most about 80° C. (e.g., at most about 70° C.,at most about 50° C., at most about 30° C., at most about 10° C., atmost about 5° C.).

In an additional aspect, the invention features a method includingincreasing a temperature of a fusing element in a battery by at leastabout 100° C. (e.g., at least about 200° C., at least about 300° C., atleast about 500° C., at least about 700° C., at least about 900° C., atleast about 1000° C., at least about 1100° C., at least about 1300° C.,at least about 1500° C., at least about 1700° C., at least about 1900°C.). The battery includes a housing, an anode and a cathode within thehousing, and a current collector at least partially disposed in theanode. The current collector includes an elongated body, in which a fuseincluding the fusing element is at least partially disposed. Thetemperature of the housing increases by at most about 80° C. (e.g., atmost about 70° C., at most about 60° C., at most about 50° C., at mostabout 40° C., at most about 30° C., at most about 20° C., at most about10° C., at most about 5° C.) when the temperature of the fusing elementis increased by at least about 100° C.

Embodiments can include one or more of the following features.

The fuse can have a current rating of about four amperes.

The fusing element can include a metal (e.g., copper). In certainembodiments, the metal can be plated. For example, the fusing elementcan include silver-plated copper. In some embodiments, the fusingelement can have a melting point of at least about 200° C. (e.g., atleast about 300° C., at least about 400° C., at least about 500° C., atleast about 600° C., at least about 800° C., at least about 1000° C., atleast about 1100° C., at least about 1200° C., at least about 1400° C.,at least about 1600° C., at least about 1800° C., at least about 1900°C.), and/or at most about 2000° C. (e.g., at most about 1900° C., atmost about 1800° C., at most about 1600° C., at most about 1400° C., atmost about 1200° C., at most about 1100° C., at most about 1000° C., atmost about 800° C., at most about 600° C., at most about 500° C., atmost about 400° C., at most about 300° C.). For example, the fusingelement can have a melting point of about 800° C.

In certain embodiments, the fusing element can have a resistance of atmost about 50 milliohms (e.g., at most about 40 milliohms, at most about30 milliohms, at most about 25 milliohms, at most about 18 milliohms, atmost about 15 milliohms, at most about 10 milliohms, at most about fivemilliohms), and/or at least about one milliohm (e.g., at least aboutfive milliohms, at least about 10 milliohms, at least about 15milliohms, at least about 18 milliohms, at least about 25 milliohms, atleast about 30 milliohms, at least about 40 milliohms).

The fusing element can have a width or diameter of at least 0.001millimeter (e.g., at least about 0.01 millimeter, at least about 0.02millimeter, at least about 0.03 millimeter, at least about 0.04millimeter, at least about 0.05 millimeter, at least about 0.1millimeter, at least about 0.2 millimeter, at least about 0.3millimeter, at least about 0.4 millimeter, at least about 0.5millimeter, at least about 0.7 millimeter, at least about 0.9millimeter, at least about one millimeter, at least about 1.2millimeters, at least about 1.4 millimeters), and/or at most about 1.5millimeters (e.g., at most about 1.4 millimeters, at most about 1.2millimeters, at most about one millimeter, at most about 0.9 millimeter,at most about 0.7 millimeter, at most about 0.5 millimeter, at mostabout 0.4 millimeter, at most about 0.3 millimeter, at most about 0.2millimeter, at most about 0.1 millimeter, at most about 0.05 millimeter,at most about 0.04 millimeter, at most about 0.03 millimeter, at mostabout 0.02 millimeter, at most about 0.01 millimeter). In someembodiments (e.g., in some embodiments in which the fusing elementincludes copper), the fusing element can have a width or diameter ofabout 0.04 millimeter.

The fusing element can have a length of at least about 0.5 millimeter(e.g., at least about 0.7 millimeter, at least about 0.9 millimeter, atleast about one millimeter, at least about two millimeters, at leastabout three millimeters, at least about four millimeters, at least aboutfive millimeters, at least about 10 millimeters, at least about 15millimeters, at least about 20 millimeters, at least about 25millimeters), and/or at most about 30 millimeters (e.g., at most about25 millimeters, at most about 20 millimeters, at most about 15millimeters, at most about 10 millimeters, at most about fivemillimeters, at most about four millimeters, at most about threemillimeters, at most about two millimeters, at most about onemillimeter, at most about 0.9 millimeter, at most about 0.7 millimeter).In certain embodiments (e.g., in certain embodiments in which the fusingelement includes copper), the fusing element can have a length of abouttwo millimeters.

The current collector can include an elongated body. In certainembodiments, the fuse can be at least partially disposed in theelongated body. The current collector can include a metal (e.g., copper)or a metal alloy (e.g., brass).

The battery can include a sleeve. The sleeve can include (e.g., can beformed of) one or more insulating materials, such as one or moreceramics, glasses, and/or plastics. In certain embodiments, the sleevecan include one or more epoxies. In certain embodiments, the sleeve caninclude a heat-shrinkable material. The sleeve can be supported by thecurrent collector. In some embodiments, the sleeve can contact thecurrent collector.

The fuse can include a matrix within which the fusing element is atleast partially disposed. The matrix can include (e.g., can be formedof) one or more insulating materials, such as one or more ceramics,glasses, and/or plastics. In some embodiments, the fusing element can beat least partially embedded in the matrix. In certain embodiments, thematrix can be integrally formed with the sleeve.

The battery can be a primary battery or a secondary battery. In someembodiments, the battery can have a cylindrical housing. In certainembodiments, the battery can include an alkaline electrolyte.

In some embodiments, the cathode can include a nickel oxyhydroxide.

The method can include melting the fusing element. In certainembodiments, melting the fusing element can include flowing a current ofat least about five amperes and/or at most about 20 amperes (e.g., atmost about 16 amperes) through the fusing element for more than about 10seconds and/or less than about 60 seconds. In some embodiments, thefusing element can melt at a current of at least about five amperes(e.g., at least about seven amperes, at least about nine amperes, atleast about 10 amperes, at least about 12 amperes, at least about 14amperes, at least about 16 amperes, at least about 18 amperes), and/orat most about 20 amperes (e.g., at most about 18 amperes, at most about16 amperes, at most about 14 amperes, at most about 12 amperes, at mostabout 10 amperes, at most about nine amperes, at most about sevenamperes). In certain embodiments, the fusing element can melt after acurrent of about 10 amperes has been flowing through the fusing elementfor at least about 0.04 second and/or at most about one second.

Embodiments can include one or more of the following advantages.

In some embodiments, a fuse can deactivate a battery even though certainparts of the battery (e.g., the housing) are at a relatively lowtemperature (e.g., about 25° C.). For example, during operation of thebattery, the temperature of the fuse (or specific components of thefuse) may become relatively high (e.g., at least about 400° C., at leastabout 600° C., at least about 800° C., at least about 1200° C., at leastabout 1600° C., at least about 1800° C.), while the temperature of thehousing of the battery is relatively low (e.g., about 25° C.). Therelatively high temperature of the fuse (or specific components of thefuse) can cause a fusing element in the fuse to melt, even though thehousing of the battery is at a relatively low temperature. When thefusing element melts, it can slow or stop current flow through thebattery, and can thereby deactivate the battery.

In certain embodiments, a battery can include a fuse that providesrelatively little resistance, even when the temperature of a fusingelement in the fuse is somewhat elevated (e.g., when the temperature ofthe fusing element is at least about 30° C., at least about 50° C., orat least about 80° C.). For example, the fuse can include a fusingelement having a resistance of at most about 50 milliohms (e.g., at mostabout 25 milliohms, at most about 18 milliohms, at most about 15milliohms, at most about 10 milliohms, at most about five milliohms). Afuse that provides relatively little resistance can allow a battery thatincludes the fuse to continue to operate, even when the temperature ofthe fusing element becomes somewhat elevated as a result of temporaryhigh-current draw situations that can occur during normal battery use.

In some embodiments, a battery that includes a fuse can be relativelysafe. For example, if the battery is short-circuited, a fusing elementin the fuse can melt, thereby limiting or preventing current flowthrough the battery, and limiting the likelihood of the batteryoverheating and/or exploding. In certain embodiments, a fuse candeactivate a battery relatively quickly (e.g., once a fusing element inthe fuse has reached a threshold elevated temperature). This can limitthe likelihood of the battery harming a user once abnormal and/orabusive battery operating conditions have occurred.

In some embodiments, a fuse can be relatively easily incorporated into abattery, and/or can be a relatively inexpensive addition to a battery.In certain embodiments, a fuse can occupy relatively little space in abattery, and can thereby provide room in the battery for othercomponents, such as electrode active materials.

In some embodiments, a battery that includes a fuse (e.g., a batteryhaving a nickel oxyhydroxide cathode) can be used for high-rateapplications (e.g., to power a digital camera and/or a cellular phone),while also being relatively safe.

Other aspects, features, and advantages of the invention are in thedrawings, description, and claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view of an embodiment of a battery.

FIG. 2 is an enlarged view of a component of the battery of FIG. 1.

FIG. 3 is an enlarged view of a component of the battery of FIG. 1.

DETAILED DESCRIPTION

Referring to FIG. 1, a battery or electrochemical cell 10 has acylindrical housing 18 containing a cathode 12, an anode 14, a separator16 between cathode 12 and anode 14, and a current collector 20. Cathode12 includes a cathode active material, and anode 14 includes an anodeactive material. Battery 10 also includes a seal 22 and a metal top cap24, which, along with current collector 20, serve as the negativeterminal for the battery. Cathode 12 is in contact with housing 18, andthe positive terminal 11 of battery 10 is at the end of the batteryopposite from the negative terminal. An electrolyte is dispersedthroughout battery 10. A battery such as battery 10 can be used, forexample, in high-rate applications, such as powering digital camerasand/or cellular phones.

FIG. 2 shows an enlarged view of current collector 20. Current collector20 has an elongated body 30 including a first portion 32 and a secondportion 34, and a fuse 40 disposed between first portion 32 and secondportion 34. Fuse 40 includes a fusing element 44 that is partiallyembedded in a matrix 48. As shown in FIGS. 1 and 2, fusing element 44extends through matrix 48, into both first portion 32 and second portion34 of elongated body 30. A sleeve 52 is wrapped around a portion ofcurrent collector 20, and contacts first portion 32, second portion 34,and fuse 40.

Fuse 40 can slow or stop current flow through battery 10 when, forexample, an operator has short-circuited battery 10. When battery 10 isshort-circuited, the current flow through battery 10 can becomerelatively high. Under conditions of high current flow, the currentflowing through fusing element 44 can cause fusing element 44 (and, insome embodiments, the environment immediately surrounding fusing element44, such as the other components of fuse 40) to increase in temperature.When fusing element 44 reaches a certain elevated temperature, fusingelement 44 can melt, thereby slowing or stopping current flow throughfusing element 44. As a result, current flow through battery 10 can slowor stop. By slowing or stopping current flow through battery 10, fuse 40can limit the likelihood of battery 10 overheating, exploding, and/orcausing a fire. In some embodiments, a fuse (e.g., fuse 40) can beincorporated into a battery (e.g., battery 10) without significantlyadversely affecting the electrochemical performance of the battery.

As shown in FIG. 3, fusing element 44 of fuse 40 has a length L and awidth or diameter W. Length L and/or width or diameter W can be selectedto increase the likelihood that fusing element 44 will melt once thecurrent flow through battery 10 has reached a threshold level. In someembodiments, length L and/or width or diameter W can be selected so thatduring periods of high current flow, the temperature of fusing element44 (and, in some embodiments, the temperature of the immediateenvironment of fusing element 44) increases significantly, while thetemperature of other regions of battery 10 (e.g., housing 18) does notincrease significantly. Thus, the ability of fuse 40 to interruptcurrent flow through battery 10 may not depend upon the overalltemperature of battery 10. As a result, in certain embodiments, fuse 40can slow or stop current flow through battery 10 relatively quickly,without depending upon an increase in the overall temperature of battery10.

In some embodiments, length L can be at least about 0.5 millimeter(e.g., at least about 0.7 millimeter, at least about 0.9 millimeter, atleast about one millimeter, at least about two millimeters, at leastabout three millimeters, at least about four millimeters, at least aboutfive millimeters, at least about 10 millimeters, at least about 15millimeters, at least about 20 millimeters, at least about 25millimeters), and/or at most about 30 millimeters (e.g., at most about25 millimeters, at most about 20 millimeters, at most about 15millimeters, at most about 10 millimeters, at most about fivemillimeters, at most about four millimeters, at most about threemillimeters, at most about two millimeters, at most about onemillimeter, at most about 0.9 millimeter, at most about 0.7 millimeter).

In certain embodiments, width or diameter W can be at least 0.001millimeter (e.g., at least about 0.01 millimeter, at least about 0.02millimeter, at least about 0.03 millimeter, at least about 0.04millimeter, at least about 0.05 millimeter, at least about 0.1millimeter, at least about 0.2 millimeter, at least about 0.3millimeter, at least about 0.4 millimeter, at least about 0.5millimeter, at least about 0.7 millimeter, at least about 0.9millimeter, at least about one millimeter, at least about 1.2millimeters, at least about 1.4 millimeters), and/or at most about 1.5millimeters (e.g., at most about 1.4 millimeters, at most about 1.2millimeters, at most about one millimeter, at most about 0.9 millimeter,at most about 0.7 millimeter, at most about 0.5 millimeter, at mostabout 0.4 millimeter, at most about 0.3 millimeter, at most about 0.2millimeter, at most about 0.1 millimeter, at most about 0.05 millimeter,at most about 0.04 millimeter, at most about 0.03 millimeter, at mostabout 0.02 millimeter, at most about 0.01 millimeter).

In some embodiments (e.g., in some embodiments in which fusing element44 includes copper), length L can be about two millimeters, and/or widthor diameter W can be about 0.04 millimeter.

Fusing element 44 can be formed of one material or more than onematerial. The materials can be selected based on, for example, the rateat which they heat up, their resistivity, their melting point, and/ortheir mechanical strength. In certain embodiments, fusing element 44 caninclude one or more metals (e.g., copper, gold, nickel) and/or metalalloys (e.g., nickel alloys). In some embodiments, fusing element 44 caninclude a plated metal, such as a silver-plated metal. For example,fusing element 44 can include silver-plated copper. In certainembodiments, fusing element 44 can include chrome. In some embodiments,fusing element 44 can include one or more materials that are selected toresult in little or no hydrogen gas evolution by fusing element 44during operation of battery 10.

In certain embodiments, fusing element 44 can include one or morematerials with a relatively high melting point. This can, for example,allow battery 10 to operate under standard operating conditions (e.g.,about 25° C., about 30° C.) without being deactivated by fuse 40. Insome embodiments, fusing element 44 can include one or more materialshaving a melting point of at least about 200° C. (e.g., at least about300° C., at least about 400° C., at least about 500° C., at least about600° C., at least about 800° C., at least about 1000° C., at least about1100° C., at least about 1200° C., at least about 1400° C., at leastabout 1600° C., at least about 1800° C., at least about 1900° C.),and/or at most about 2000° C. (e.g., at most about 1900° C., at mostabout 1800° C., at most about 1600° C., at most about 1400° C., at mostabout 1200° C., at most about 1100° C., at most about 1000° C., at mostabout 800° C., at most about 600° C., at most about 500° C., at mostabout 400° C., at most about 300° C.). For example, fusing element 44can include one or more materials having a melting point of from about500° C. to about 1200° C. (e.g., from about 800° C. to about 1100° C.,about 800° C., about 1064° C., about 1083° C.). In some embodiments,fusing element 44 can include one or more materials having a meltingpoint of about 1900° C.

In certain embodiments, fusing element 44 can have a resistance of atmost about 50 milliohms (e.g., at most about 25 milliohms, at most about18 milliohms, at most about 15 milliohms, at most about 10 milliohms, atmost about five milliohms).

In some embodiments, fusing element 44 can be adapted to melt at arelatively high temperature while housing 18 is at a relatively lowtemperature. For example, in certain embodiments, fusing element 44 canbe adapted to melt at a temperature of at least about 200° C. (e.g., atleast about 300° C., at least about 400° C., at least about 500° C., atleast about 600° C., at least about 800° C., at least about 1000° C., atleast about 1100° C., at least about 1200° C., at least about 1400° C.,at least about 1600° C., at least about 1800° C., at least about 1900°C.), while housing 18 is at a temperature of at most about 90° C. (e.g.,at most about 87° C., at most about 80° C., at most about 79° C., atmost about 70° C., at most about 60° C., at most about 50° C., at mostabout 40° C., at most about 30° C., at most about 25° C.). In someembodiments, fusing element 44 can melt while housing 18 is at atemperature of from about 20° C. to about 25° C. (e.g., from about 23°C. to about 24° C.).

In some embodiments, fusing element 44 can be adapted to melt when thecurrent flowing through fusing element 44 is at least about five amperes(e.g., at least about six amperes, at least about seven amperes, atleast about eight amperes, at least about nine amperes, at least about10 amperes, at least about 11 amperes, at least about 12 amperes, atleast about 13 amperes, at least about 14 amperes, at least about 15amperes, at least about 16 amperes, at least about 17 amperes, at leastabout 18 amperes, at least about 19 amperes), and/or at most about 20amperes (e.g., at most about 19 amperes, at most about 18 amperes, atmost about 17 amperes, at most about 16 amperes, at most about 15amperes, at most about 14 amperes, at most about 13 amperes, at mostabout 12 amperes, at most about 11 amperes, at most about 10 amperes, atmost about nine amperes, at most about eight amperes, at most aboutseven amperes, at most about six amperes). For example, fusing element44 may be adapted to melt when the current flowing through fusingelement 44 is about five amperes, about six amperes, about sevenamperes, about eight amperes, about nine amperes, about 10 amperes,about 11 amperes, about 12 amperes, about 13 amperes, about 14 amperes,about 15 amperes, about 16 amperes, about 17 amperes, about 18 amperes,about 19 amperes, or about 20 amperes.

In some embodiments, fusing element 44 can be melted by flowing acurrent of at least about five amperes and/or at most about 20 amperes(e.g., about 13 amperes) through fusing element 44.

In some embodiments, fusing element 44 can be adapted to melt after atleast 0.005 second (e.g., at least about 0.01 second, at least about0.04 second, at least about 0.1 second, at least about 0.5 second, atleast about one second, at least about two seconds, at least about threeseconds, at least about four seconds, at least about five seconds, atleast about 10 seconds, at least about 15 seconds, at least about 20seconds, at least about 40 seconds) and/or at most about 60 seconds(e.g., at most about 40 seconds, at most about 20 seconds, at most about15 seconds, at most about 10 seconds, at most about five seconds, atmost about four seconds, at most about three seconds, at most about twoseconds, at most about one second, at most about 0.5 second, at mostabout 0.1 second, at most about 0.04 second, at most about 0.01 second)of current flowing through fusing element 44.

In certain embodiments, fusing element 44 can melt after at least 0.005second (e.g., at least about 0.01 second, at least about 0.04 second, atleast about 0.1 second, at least about 0.5 second, at least about onesecond, at least about two seconds, at least about three seconds, atleast about four seconds, at least about five seconds, at least about 10seconds, at least about 15 seconds, at least about 20 seconds, at leastabout 40 seconds), and/or at most about 60 seconds (e.g., at most about40 seconds, at most about 20 seconds, at most about 15 seconds, at mostabout 10 seconds, at most about five seconds, at most about fourseconds, at most about three seconds, at most about two seconds, at mostabout one second, at most about 0.5 second, at most about 0.1 second, atmost about 0.04 second, at most about 0.01 second), of a 10-amperecurrent flowing through fusing element 44.

In certain embodiments, fusing element 44 can be melted by flowing acurrent through fusing element 44 for more than about 10 seconds (e.g.,at least about 15 seconds, at least about 20 seconds, at least about 30seconds, at least about 40 seconds, at least about 50 seconds), and/orless than about 60 seconds (e.g., at most about 50 seconds, at mostabout 40 seconds, at most about 30 seconds, at most about 20 seconds, atmost about 15 seconds).

In some embodiments, fusing element 44 can be melted by flowing acurrent of about 13 amperes through fusing element 44 for about 14milliseconds or about 40 milliseconds.

In some embodiments, during operation of battery 10, the temperature offusing element 44 can increase by at least about 100° C. (e.g., at leastabout 200° C., at least about 300° C., at least about 500° C., at leastabout 700° C., at least about 900° C., at least about 1000° C., at leastabout 1100° C., at least about 1300° C., at least about 1500° C., atleast about 1700° C., at least about 1900° C.), and/or at most about2000° C. (e.g., at most about 1900° C., at most about 1700° C., at mostabout 1500° C., at most about 1300° C., at most about 1100° C., at mostabout 900° C., at most about 700° C., at most about 500° C., at mostabout 400° C., at most about 300° C., at most about 200° C.). In certainembodiments, while the temperature of fusing element 44 is increasing,the temperature of housing 18 can increase by at most about 80° C.(e.g., at most about 70° C., at most about 60° C., at most about 50° C.,at most about 40° C., at most about 30° C., at most about 20° C., atmost about 10° C., at most about 5° C.). In some embodiments, thetemperature of fusing element 44 can increase, while the temperature ofhousing 18 does not increase at all.

In certain embodiments, one or more of the aspects of fusing element 44(e.g., length L, width or diameter W, the materials out of which fusingelement 44 is formed) can be selected so that battery 10 is notdeactivated during transient high current situations that can beencountered during normal product usage. Transient high currentsituations can occur, for example, during battery insertion and/orduring extreme conditions of device usage. For example, when a motor isused in relatively cold temperatures, the motor may draw a relativelylarge current when starting up, and may thereafter draw a smallercurrent.

The current rating of fuse 40 can be selected based on the desiredcurrent draw during use of battery 10. For example, in some embodiments,the current rating of fuse 40 can be selected to be higher than thedesired current drain during use of battery 10. Generally, as thecurrent rating of a fuse decreases, the resistance of the fuse canincrease. In certain embodiments, fuse 40 can have a current rating of,for example, about four amperes.

An example of a commercially available fuse is the model 251 4.0 amppico fuse from Littelfuse® (Des Plaines, Ill.).

As described above, in addition to including fusing element 44, fuse 40also includes matrix 48, which can provide structural support for fusingelement 44. Matrix 48 can include one or more materials that areselected to provide matrix 48 with mechanical strength. In someembodiments, matrix 48 can include (e.g., can be formed of) one or moreinsulating materials. As used herein, an insulating material can be amaterial having a resistivity of at least 1×10⁵ ohm-cm. Examples ofinsulating materials include plastics, glasses, ceramics, andcombinations thereof. In some embodiments, matrix 48 can include one ormore epoxies. In certain embodiments, matrix 48 can include (e.g., canbe formed of) one or more materials that are covered with a chemicallyinert coating. In some embodiments, matrix 48 can include (e.g., can beformed of) one or more of the same materials as sleeve 52.

In certain embodiments, matrix 48 can be attached to first portion 32and/or second portion 34. Matrix 48 can be attached to first portion 32and/or second portion 34 using, for example, an adhesive.

As shown in FIGS. 1 and 2, sleeve 52 is wrapped around fuse 40 and aportion of elongated body 30 of current collector 20, and is immersed inanode 14. Sleeve 52, which includes (e.g., is formed of) one or moreinsulating materials, can limit the likelihood of a currentcircumventing fusing element 44 by shorting across fusing element 44.Examples of insulating materials include plastics, glasses, ceramics,and combinations thereof. In some embodiments, sleeve 52 can include oneor more epoxies. In certain embodiments, sleeve 52 can include (e.g.,can be formed of) one or more materials that are covered with achemically inert coating. In some embodiments, sleeve 52 can include oneor more heat-shrinkable materials. The heat-shrinkable materials canallow sleeve 52 to be heat-shrunk around elongated body 30 of currentcollector 20.

In certain embodiments, sleeve 52 can be attached to first portion 32and/or second portion 34 of elongated body 30, and/or can be attached tomatrix 48. Sleeve 52 can be attached to first portion 32, second portion34, and/or matrix 48 using, for example, an adhesive. In certainembodiments, sleeve 52 can be integrally formed with matrix 48.

First portion 32 and/or second portion 34 of elongated body 30 ofcurrent collector 20 can include (e.g., can be formed of) the samematerials or different materials. In some embodiments, first portion 32and/or second portion 34 can include one or more metals and/or metalalloys, such as copper or brass (e.g., an alloy of 60% zinc and 40%copper). The metals and/or metal alloys can be plated (e.g.,tin-plated). In certain embodiments, first portion 32 and/or secondportion 34 can include tin-plated copper. In some embodiments, themetals and/or metal alloys can be selected to limit the likelihood ofaccelerating self-discharge of anode 14, and/or to limit the likelihoodof adding significant resistance to battery 10. In certain embodiments,first portion 32 and/or second portion 34 can include one or morematerials that are selected to be compatible with a zinc anode slurry.

Fusing element 44 can be attached to first portion 32 and/or secondportion 34 of elongated body 30 of current collector 20 by, for example,soldering.

Cathode 12 includes at least one (e.g., two, three) cathode activematerial. In some embodiments, cathode 12 can further include at leastone conductive aid and/or at least one binder. The electrolyte also isdispersed through cathode 12. The weight percentages provided hereinwith respect to components of cathode 12 are determined after theelectrolyte has been dispersed through cathode 12.

In some embodiments, the cathode active material can be a manganeseoxide, such as manganese dioxide (MnO₂). The manganese dioxide can beelectrolytically-synthesized MnO₂ (EMI), chemically-synthesized MnO₂(CMD), or a blend of EMD and CMD. Distributors of manganese dioxidesinclude Kerr-McGee Corp. (manufacturer of, e.g., Trona D and high-powerEMD), Tosoh Corp., Delta Manganese, Delta EMD Ltd., Mitsui Chemicals,ERACHEM, and JMC. In certain embodiments, cathode 12 can include fromabout 80 percent to about 88 percent by weight (e.g., from about 82percent to about 86 percent by weight) manganese dioxide (e.g., EMD).

Other examples of cathode active materials include copper oxides (e.g.,cupric oxide (CuO), cuprous oxide (Cu₂O)); copper hydroxides (e.g.,cupric hydroxide (Cu(OH)₂), cuprous hydroxide (Cu(OH))); cupric iodate(Cu(IO₃)₂); AgCuO₂; LiCuO₂; Cu(OH)(IO₃); Cu₂H(IO₆); copper-containingmetal oxides or chalcogenides; copper halides (e.g., CUCl₂); and/orcopper manganese oxides (e.g., Cu(MnO₄)₂). The copper oxides can bestoichiometric (e.g., CuO) or non-stoichiometric (e.g., CuO_(x), where0.5≦x≦1.5). Another example of a cathode active material is Cu₆InO₈Cl.

Further examples of cathode active materials include cathode activematerials that include nickel, such as a nickel oxyhydroxide (NiOOH).The nickel oxyhydroxide can include, for example, a beta-nickeloxyhydroxide, a cobalt oxyhydroxide-coated beta-nickel oxyhydroxide, agamma-nickel oxyhydroxide, a cobalt oxyhydroxide-coated gamma-nickeloxyhydroxide, a solid solution of a beta-nickel oxyhydroxide and agamma-nickel oxyhydroxide, or a cobalt oxyhydroxide-coated solidsolution of a beta-nickel oxyhydroxide and a gamma-nickel oxyhydroxide.

Additional examples of cathode active materials include cathode activematerials including a pentavalent bismuth-containing metal oxide.

In certain embodiments, cathode 12 can be porous. A porous cathode caninclude, for example, one or more of the above-described cathode activematerials (e.g., EMD, NiOOH).

The conductive aid can increase the electronic conductivity of cathode12. An example of a conductive aid is carbon particles. The carbonparticles can be any of the conventional carbon particles used incathodes. The carbon particles can be, for example, graphite particles.Graphite particles that are used in cathode 12 can be any of thegraphite particles used in cathodes. The particles can be synthetic,non-synthetic, or a blend of synthetic and non-synthetic, and they canbe expanded or non-expanded. In certain embodiments, the graphiteparticles are non-synthetic, non-expanded graphite particles. In suchembodiments, the graphite particles can have an average particle size ofless than about 20 microns (e.g., from about two microns to about 12microns, from about five microns to about nine microns), as measuredusing a Sympatec HELIOS analyzer. Graphite particles can be obtainedfrom, for example, Brazilian Nacional de Grafite (Itapecirica, MG Brazil(MP-0702X)) or Chuetsu Graphite Works, Ltd. (Chuetsu grades WH-20A andWH-20AF) of Japan. Cathode 12 may include for example, from about threepercent to about nine percent (e.g., from about four percent to aboutseven percent) carbon particles by weight. In some embodiments, cathode12 can include from about four percent to about nine percent (e.g., fromabout four percent to about 6.5 percent) graphite particles by weight.

Another example of a conductive aid is carbon fibers, such as thosedescribed in Luo et al., U.S. Pat. No. 6,858,349, and in Anglin, U.S.Patent Application Publication No. US 2002/0172867 A1, published on Nov.21, 2002, and entitled “Battery Cathode”. In some embodiments, cathode12 can include less than about two percent by weight (e.g., less thanabout 1.5 percent by weight, less than about one percent by weight, lessthan about 0.75 percent by weight, less than about 0.5 percent byweight), and/or more than about 0.1 percent by weight (e.g., more thanabout 0.2 percent by weight, more than about 0.3 percent by weight, morethan about 0.4 percent by weight, more than about 0.45 percent byweight) carbon fibers.

In certain embodiments, cathode 12 can include from about one percent byweight to about 10 percent by weight of one or more total conductiveaids.

A cathode can be made by coating a cathode material onto a currentcollector, and drying and then calendering the coated current collector.The cathode material can be prepared by mixing the cathode activematerial together with other components, such as a binder,solvent/water, and a carbon source. For example, a cathode activematerial such as MnO₂ may be combined with carbon (e.g., graphite,acetylene black), and mixed with small amount of water to form a cathodeslurry. A current collector can then be coated with the cathode slurryto form the cathode.

Examples of binders include polyethylene powders, polyacrylamides,Portland cement and fluorocarbon resins, such as polyvinylidenefluoride(PVDF) and polytetrafluoroethylene (PTFE). An example of a polyethylenebinder is sold under the trade name Coathylene HA-1681 (available fromHoechst). Cathode 12 may include, for example, up to about two percentbinder by weight (e.g., up to about one percent binder by weight). Incertain embodiments, cathode 12 can include from about 0.1 percent toabout two percent (e.g., from about 0.1 percent to about one percent)binder by weight.

Cathode 12 can include other additives. Additives are disclosed, forexample, in Mieczkowska et al., U.S. Pat. No. 5,342,712. In someembodiments, cathode 12 can include titanium dioxide (TiO₂). In certainembodiments, cathode 12 can include from about 0.1 percent to about twopercent (e.g., from about 0.2 percent to about two percent) TiO₂ byweight.

Cathodes (e.g., cathode active materials) are described, for example, inDurkot et al., U.S. Patent Application Publication No. US 2004/0237293A1, published on Dec. 2, 2004, and entitled “Alkaline Cell With FlatHousing and Nickel Oxyhydroxide Cathode”; Durkot et al., U.S. PatentApplication Publication No. US 2004/0197656 A1, published on Oct. 7,2004, and entitled “Alkaline Battery Including Nickel OxyhydroxideCathode and Zinc Anode”; Bowden et al., U.S. Patent ApplicationPublication No. US 2004/0076881 A1, published on Apr. 22, 2004, andentitled “Method of Making a Battery”; Eylem et al., U.S. PatentApplication Publication No. US 2005/0136328 A1, published on Jun. 23,2005, and entitled “Battery Cathode”; Christian et al., U.S. PatentApplication Publication No. US 2004/0043292 A1, published on Mar. 4,2004, and entitled “Alkaline Battery Including Nickel OxyhydroxideCathode and Zinc Anode”; Christian et al., U.S. Patent ApplicationPublication No. US 2004/0202931 A1, published on Oct. 14, 2004, andentitled “Preparation of Nickel Oxyhydroxide”; Eylem et al., U.S. PatentApplication Publication No. US 2005/0058903 A1, published on Mar. 17,2005, and entitled “Primary Alkaline Battery Containing Bismuth MetalOxide”; Wang et al., U.S. Patent Application Publication No. US2005/0058902 A1, published on Mar. 17, 2005, and entitled “PrimaryAlkaline Battery Containing Bismuth Metal Oxide”; and Kelsey et al.,U.S. Pat. No. 6,207,322.

The electrolyte that is dispersed through cathode 12 (and/or theelectrolyte used in the rest of battery 10) can be any of theelectrolytes used in batteries. In some embodiments, cathode 12 caninclude from about five percent to about eight percent (e.g., from aboutsix percent to about seven percent) electrolyte by weight. Theelectrolyte can be aqueous or non-aqueous. An aqueous electrolyte can bean alkaline solution, such as an aqueous hydroxide solution (e.g., LiOH,NaOH, KOH), or a mixture of hydroxide solutions (e.g., NaOH/KOH). Forexample, the aqueous hydroxide solution can include from about 33percent by weight to about 40 percent by weight of the hydroxidematerial, such as about 9N KOH (about 37 percent by weight KOH). In someembodiments, the electrolyte can also include up to about four percentby weight (e.g., about two percent by weight) of zinc oxide.

The electrolyte can include other additives. As an example, theelectrolyte can include a soluble material (e.g., an aluminum material)that reduces (e.g., suppresses) the solubility of the cathode activematerial in the electrolyte. In certain embodiments, the electrolyte caninclude one or more of the following: aluminum hydroxide, aluminumoxide, alkali metal aluminates, aluminum metal, alkali metal halides,alkali metal carbonates, or mixtures thereof. Electrolyte additives aredescribed, for example, in Eylem et al., U.S. Patent ApplicationPublication No. US 2004/0175613 A1, published on Sep. 9, 2004, andentitled “Battery”.

Housing 18 can be any housing commonly used in batteries. As shown,housing 18 is a cylindrical housing. However, housings with othershapes, such as prismatic housings, can be used. In some embodiments,housing 18 can be made of a metal or a metal alloy, such as nickel,nickel-plated steel (e.g., nickel-plated cold-rolled steel), stainlesssteel, aluminum-clad stainless steel, aluminum, or an aluminum alloy. Incertain embodiments, housing 18 can be made of a plastic, such aspolyvinyl chloride, polypropylene, a polysulfone, acrylonitrilebutadiene styrene (ABS), or a polyamide.

In some embodiments, housing 18 can include an inner metal wall and anouter electrically non-conductive material such as heat-shrinkableplastic. Optionally, a layer of conductive material can be disposedbetween the inner wall and cathode 12. The layer may be disposed alongthe inner surface of the inner wall, along the circumference of cathode12, or both. This conductive layer can be formed, for example, of acarbonaceous material (e.g., graphite). Such materials include, forexample, LB1000 (Timcal), Eccocoat 257 (W.R. Grace & Co.), Electrodag109 (Acheson Colloids Co.), Electrodag 112 (Acheson), Varniphite 5000(Nippon), and EB0005 (Acheson). Methods of applying the conductive layerare disclosed, for example, in Canadian Patent No. 1,263,697.

Anode 14 can be formed of any of the zinc materials used in batteryanodes. For example, anode 14 can be a zinc gel that includes zinc metalparticles, a gelling agent, and minor amounts of additives, such asgassing inhibitor. In addition, a portion of the electrolyte isdispersed throughout the anode.

The zinc particles can be any of the zinc particles (e.g., zinc fines)used in gel anodes. Examples of zinc particles include those describedin Durkot et al., U.S. Pat. No. 6,284,410, and in Durkot et al., U.S.Pat. No. 6,521,378. In certain embodiments, anode 14 can includespherical zinc particles. Spherical zinc particles are described, forexample, in Costanzo et al., U.S. Patent Application Publication No. US2004/0258995 A1, published on Dec. 23, 2004, and entitled “Anode forBattery”. The zinc particles can be a zinc alloy (e.g., containing a fewhundred parts per million of indium and bismuth). Anode 14 may include,for example, from about 40 percent to about 90 percent (e.g., from about67 percent to about 80 percent) zinc particles by weight.

Examples of gelling agents include polyacrylic acids, grafted starchmaterials, salts of polyacrylic acids, polyacrylates,carboxymethylcellulose or combinations thereof. Examples of polyacrylicacids include Carbopol 940 and 934 (available from Noveon Inc.) andPolygel 4P (available from 3V). An example of a grafted starch materialis Waterlock A221 (available from Grain Processing Corporation,Muscatine, Iowa). An example of a salt of a polyacrylic acid is AlcosorbG1 (available from Ciba Specialties). Anode 14 may include, for example,from about 0.1 percent to about one percent gelling agent by weight.

Gassing inhibitors can be inorganic materials, such as bismuth, tin,lead and indium. Alternatively, gassing inhibitors can be organiccompounds, such as phosphate esters, ionic surfactants or nonionicsurfactants. Examples of ionic surfactants are disclosed, for example,in Chalilpoyil et al., U.S. Pat. No. 4,777,100.

Separator 16 can be formed of any of the standard separator materialsused in electrochemical cells (e.g., alkaline cells). For example,separator 16 can be formed of polypropylene (e.g., non-wovenpolypropylene or microporous polypropylene), polyethylene,polytetrafluoroethylene, a polyamide (e.g., a nylon), a polysulfone, apolyvinyl chloride, or combinations thereof. In some embodiments,separator 16 can include a layer of cellophane combined with a layer ofa non-woven material. The non-woven material can include, for example,polyvinyl alcohol and/or rayon.

Seal 22 can be made of, for example, a polymer (e.g., nylon).

Cap 24 can be made of, for example, a metal or a metal alloy, such asaluminum, nickel, titanium, or steel.

In some embodiments, battery 10 can include a hydrogen recombinationcatalyst to lower the amount of hydrogen gas that may be generated inthe cell by anode 14 (e.g., when anode 14 includes zinc). Hydrogenrecombination catalysts are described, for example, in Davis et al.,U.S. Pat. No. 6,500,576, and in Kozawa, U.S. Pat. No. 3,893,870.Alternatively or additionally, battery 10 can be constructed to includepressure-activated valves or vents, such as those described inTomantschger et al., U.S. Pat. No. 5,300,371.

Weight percentages of battery components provided herein are determinedafter the electrolyte solution has been dispersed in the battery.

Battery 10 can be a primary electrochemical cell or a secondaryelectrochemical cell. Primary cells are meant to be discharged (e.g., toexhaustion) only once, and then discarded. Primary cells are notintended to be recharged. Primary cells are described, for example, inDavid Linden, Handbook of Batteries (McGraw-Hill, 2d ed. 1995).Secondary electrochemical cells can be recharged for many times (e.g.,more than fifty times, more than a hundred times, or more). In someembodiments, secondary cells can include relatively robust separators,such as separators that have many layers and/or separators that arerelatively thick. Secondary cells can also be designed to accommodatefor changes, such as swelling, that can occur in the cells. Secondarycells are described, for example, in Falk & Salkind, “Alkaline StorageBatteries”, John Wiley & Sons, Inc. 1969, and in Virloy et al., U.S.Pat. No. 345,124.

Battery 10 can be of any of a number of different voltages (e.g., 1.5 V,3.0 V, 4.0 V), and/or can be, for example, a AA, AAA, AAAA, C, or Dbattery. While battery 10 is cylindrical, in some embodiments, a batterycan be non-cylindrical. For example, a battery can be a coin cell, abutton cell, a wafer cell, or a racetrack-shaped cell. In someembodiments, a battery can be prismatic. In certain embodiments, abattery can have a rigid laminar cell configuration or a flexible pouch,envelope or bag cell configuration. In some embodiments, a battery canhave a spirally wound configuration, or a flat plate configuration.Batteries are described, for example, in Bedder et al., U.S. Pat. No.4,622,277; McVeigh, Jr. et al., U.S. Pat. No. 4,707,421; Batson et al.,U.S. Pat. No. 6,001,504; Berkowitz et al., U.S. patent application Ser.No. 10/675,512, filed on Sep. 30, 2003, and entitled “Batteries”; Totiret al., U.S. patent application Ser. No. 10/800,905, filed on Mar. 15,2004, and entitled “Non-Aqueous Electrochemical Cells”; Durkot et al.,U.S. Patent Application Publication No. US 2004/0237293 A1, published onDec. 2, 2004, and entitled “Alkaline Cell With Flat Housing and NickelOxyhydroxide Cathode”; and Berkowitz et al., U.S. Patent ApplicationPublication No. US 2005/0112467 A1, published on May 26, 2005, andentitled “Battery Including Aluminum Component”.

A cell (e.g., a cylindrical cell) can be prepared by, for example,rolling an anode, separator, and cathode together, and placing them in ahousing. The housing (containing the anode, the cathode, and theseparator) can then be filled with the electrolytic solution andsubsequently hermetically sealed with, for example, a cap and annularinsulating gasket.

In some embodiments, a cell (e.g., a cylindrical cell) can be preparedby spirally winding an anode, a cathode, and a separator together, witha portion of the cathode current collector extending axially from oneend of the roll. The portion of the current collector that extends fromthe roll can be free of cathode active material. To connect the currentcollector with an external contact, the exposed end of the currentcollector can be welded to a metal tab, which is in electric contactwith an external battery contact. The grid can be rolled in the machinedirection, the pulled direction, perpendicular to the machine direction,or perpendicular to the pulled direction. The tab can be welded to thegrid to minimize the conductivity of grid and tab assembly.Alternatively, the exposed end of the current collector can be inmechanical contact (e.g., not welded) with a positive lead which is inelectric contact with an external battery contact. A cell having amechanical contact and not having a welded contact can require fewerparts and steps to manufacture than a cell with a welded contact. Incertain embodiments, the effectiveness of the mechanical contact can beenhanced by bending the exposed grid towards the center of the roll tocreate a dome or crown, with the highest point of the crown over theaxis of the roll, corresponding to the center of a cylindrical cell. Inthe crown configuration, the grid can have a denser arrangement ofstrands than in the non-shaped form. A crown can be orderly folded andthe dimensions of a crown can be precisely controlled.

Methods for assembling electrochemical cells are described, for example,in Moses, U.S. Pat. No. 4,279,972; Moses et al., U.S. Pat. No.4,401,735; and Kearney et al., U.S. Pat. No. 4,526,846.

While certain embodiments have been described, other embodiments arepossible.

As an example, while a battery including a fuse that is disposed in ananode current collector has been described, in certain embodiments, abattery can alternatively or additionally include a fuse that isdisposed in a cathode current collector.

As another example, while a battery including a fuse that is disposed ina current collector has been described, in some embodiments, a batterycan include a fuse in one or more other locations. A fuse can belocated, for example, in any region of a battery in which electrons arecollected from the battery active material during discharge of thebattery. For example, in some embodiments, a fuse can be located betweena node of a battery (e.g., the positive terminal of the battery) and thecontact between the node and a device being powered by the battery. Incertain embodiments, a terminal of the battery (e.g., the positiveterminal) can include a fuse. For example, a terminal of a battery canbe formed of a fuse. In some embodiments, a fuse in a battery can be incontact with one of the electrodes of the battery (e.g., the anode),while not being in contact with another electrode of the battery. Incertain embodiments, multiple (e.g., two, three, four, five, 10)electrochemical cells can be used together to form a battery pack. Oneor more fuses can be located between electrochemical cells in thebattery pack.

As a further example, while a battery including a sleeve has beendescribed, in certain embodiments, a battery may not include a sleeve.In some embodiments, a battery can include one or more insulatingmaterials that are not in the form of a sleeve. For example, a batterycan include one or more strips of insulating materials that are attachedto a current collector of the battery.

As another example, in some embodiments, a battery can include multiple(e.g., two, three, four, five) fuses.

As an additional example, in certain embodiments, a battery can includeat least one thermally activated current interrupt mechanism, such asone of the thermally activated current interrupt mechanisms disclosed inVu et al., U.S. Pat. No. 5,750,277.

As another example, in certain embodiments, one or more miniaturechip-type fuses can be used in a battery. In some embodiments, aminiature chip-type fuse can be used in conjunction with one or morescreens (e.g., that serve as current collectors) and/or batteryconnectors. In certain embodiments, a miniature chip-type fuse can belocated at one or more contact points between a battery and a devicethat is powered by the battery.

As an additional example, while a current collector including anelongated body and a fuse between two portions of the elongated body hasbeen shown, in some embodiments, a current collector can have adifferent configuration. For example, in certain embodiments, a currentcollector may be formed entirely of a fuse, and may not include anelongated body that is separate from the fuse. In some embodiments, oneor more of the leads extending from a fuse can be used as a currentcollector. The leads can be formed of one or more materials (e.g., metalalloys) that are not likely to react with the electrode active materialwith which the leads are in contact. In certain embodiments, a currentcollector can be formed of an elongated body and a fuse that is disposedat one end of the elongated body, rather than between two portions ofthe elongated body.

As a further example, while a fuse including a matrix has beendescribed, in some embodiments, a fuse may not include a matrix. Forexample, in certain embodiments, a current collector can include a body(e.g., an elongated body), at least a portion of which is formed by afusing element. In some embodiments, a current collector can be formedentirely of a fusing element.

All references, such as patent applications, publications, and patents,referred to herein are incorporated by reference in their entirety.

Other embodiments are in the claims.

1. A battery, comprising: a housing; an anode within the housing; a cathode within the housing; and a current collector at least partially disposed in the anode and comprising a fuse, wherein the fuse comprises a fusing element having a melting point of at least about 200° C.
 2. The battery of claim 1, wherein the fusing element has a melting point of at least about 400° C.
 3. The battery of claim 1, wherein the fusing element has a melting point of at least about 800° C.
 4. The battery of claim 1, wherein the fusing element has a melting point of about 800° C.
 5. The battery of claim 1, wherein the fusing element has a melting point of at most about 2000° C.
 6. The battery of claim 1, wherein the fusing element has a melting point of at most about 1100° C.
 7. The battery of claim 1, wherein the current collector comprises an elongated body and the fuse is at least partially disposed in the elongated body.
 8. The battery of claim 1, further comprising a sleeve supported by the current collector.
 9. The battery of claim 8, wherein the sleeve contacts the current collector.
 10. The battery of claim 8, wherein the sleeve comprises a material that is selected from the group consisting of plastics, ceramics, glasses, and combinations thereof.
 11. The battery of claim 8, wherein the sleeve comprises a heat-shrinkable material.
 12. The battery of claim 1, wherein the current collector comprises a metal or a metal alloy.
 13. The battery of claim 1, wherein the current collector comprises brass.
 14. The battery of claim 1, wherein the cathode comprises a nickel oxyhydroxide.
 15. The battery of claim 1, wherein the battery is a primary battery.
 16. Abattery, comprising: a housing; an anode within the housing; a cathode within the housing; and a current collector at least partially disposed in the anode and comprising a fuse comprising a fusing element, wherein the fuising element is adapted to melt at a temperature of at least about 200° C. while the housing is at a temperature of at most about 90° C.
 17. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 400° C. while the housing is at a temperature of at most about 90° C.
 18. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 800° C. while the housing is at a temperature of at most about 90° C.
 19. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 1000° C. while the housing is at a temperature of at most about 90° C.
 20. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 200° C. while the housing is at a temperature of at most about 70° C.
 21. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 200° C. while the housing is at a temperature of at most about 50° C.
 22. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 200° C. while the housing is at a temperature of at most about 30° C.
 23. The battery of claim 16, wherein the fusing element is adapted to melt at a temperature of at least about 200° C. while the housing is at a temperature of at most about 25° C.
 24. A method of making a battery, the method comprising: disposing an anode into a housing; disposing a cathode into the housing; and disposing a current collector into the housing, wherein the current collector comprises an elongated body and a fuse at least partially disposed in the elongated body, the fuse comprising a fusing element having a melting point of at least about 200° C.
 25. A method of making a battery, the method comprising: disposing an anode into a housing; disposing a cathode into the housing; and disposing a current collector into the housing, wherein the current collector comprises a fuse comprising a fusing element, and the fusing element is adapted to melt at a temperature of at least about 200° C. while the housing is at a temperature of at most about 90° C.
 26. A method, comprising: flowing a current through a battery comprising: a housing; an anode within the housing; a cathode within the housing; and a current collector at least partially disposed in the anode and comprising an elongated body and a fuse at least partially disposed in the elongated body, the fuse comprising a fusing element; and increasing a temperature of the fusing element by at least about 100° C. while a temperature of the housing increases by at most about 80° C.
 27. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 300° C. while a temperature of the housing increases by at most about 80° C.
 28. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 500° C. while a temperature of the housing increases by at most about 80° C.
 29. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 900° C. while a temperature of the housing increases by at most about 80° C.
 30. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 100° C. while a temperature of the housing increases by at most about 50° C.
 31. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 100° C. while a temperature of the housing increases by at most about 30° C.
 32. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 100° C. while a temperature of the housing increases by at most about 10° C.
 33. The method of claim 26, comprising increasing a temperature of the fusing element by at least about 100° C. while a temperature of the housing increases by at most about 5° C.
 34. The method of claim 26, further comprising melting the fusing element.
 35. The method of claim 34, wherein the fusing element melts at a current of at least about five amperes.
 36. The method of claim 34, wherein the fusing element melts at a current of at most about 20 amperes.
 37. The method of claim 34, wherein the fusing element melts after a current of about 10 amperes has been flowing through the fusing element for at least about 0.04 second.
 38. The method of claim 37, wherein the fusing element melts after a current of about 10 amperes has been flowing through the fusing element for at most about one second.
 39. The method of claim 34, wherein melting the fusing element comprises flowing a current of at least about five amperes through the fusing element for more than about 10 seconds.
 40. The method of claim 34, wherein melting the fusing element comprises flowing a current of at least about five amperes through the fusing element for less than about 60 seconds.
 41. The method of claim 34, wherein melting the fusing element comprises flowing a current of at most about 16 amperes through the fusing element for more than about 10 seconds.
 42. The method of claim 34, wherein melting the fusing element comprises flowing a current of at most about 16 amperes through the fusing element for less than about 60 seconds.
 43. A method, comprising: increasing a temperature of a fusing element in a battery by at least about 100° C., the battery comprising: a housing, an anode within the housing, a cathode within the housing, and a current collector at least partially disposed in the anode and comprising an elongated body and a fuse at least partially disposed in the elongated body, the fuse comprising the fusing element, wherein a temperature of the housing increases by at most about 80° C. while the temperature of the fusing element is increased by at least about 100° C. 